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Reliable, Safe and Energy/Water-Efficient Systems Powering Automation
October 2021
Measurement
F ood & B everage P rocessing
& P ackaging M onthly F eature
16 Tetra Pak Solutions
6 Corporate GHG-Reduction News Conserve Water & Energy
for Food & Bev Sector
22 Preparing Reciprocating Air
Compressors for Winter
26 Sustainability with Optimal
Air Compressor Lubricant
32 Metal and Plastic Piping
for Compressed Air
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O C T O B E R 2 0 2 1 | V O L U M E 1 6 , N O . 9
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QUALITY, SAFETY & RELIABILITY FEATURES
22 Preparing Reciprocating Air Compressors for Winter
By the Compressed Air & Gas Institute
32 Both Metal and Plastic Pipe Necessary for Compressed
Air Applications
By Rob Marsiglia, Asahi America
40 Pure Gas Testing – The Benefits of Point of Use Sampling 16
By Jenny Palkowitsh, Trace Analytics
SUSTAINABILITY & ENERGY/WATER EFFICIENCY FEATURES
16 Tetra Pak Solutions Conserve Water
& Energy for Food & Beverage Sector
By Mike Grennier, Compressed Air
Best Practices® Magazine
26 Promote Sustainability with an Optimal Air
22 Compressor Lubricant
By Jasween Jagjit-Webb, Klüber Lubrication
SUSTAINABILITY & EFFICIENT TECHNOLOGY NEWS
6 Corporate GHG-Reduction News
Featuring: Signify, Merck and PepsiCo
44 Compressed Air Technology
32
EVERY ISSUE
4 From the Editor 48 Advertiser Index 48 The Marketplace | Jobs and Technology
Compressed Air Best Practices ® (USPS# 17130) is published monthly except January-February combined by Smith Onandia Communications LLC, 37 McMurray Rd., Suite 104, Pittsburgh, PA 15241.
Periodicals postage paid at Pittsburgh, PA and additional mailing offices. POSTMASTER: Send address changes to: Compressed Air Best Practices ®, 37 McMurray Rd, Suite 104, Pittsburgh, PA 15241.
Compressed Air Best Practices ® is a trademark of Smith Onandia Communications, LLC. Publisher cannot be held liable for non-delivery due to circumstances beyond its control. No refunds. SUBSCRIPTIONS: Qualified reader
subscriptions are accepted from compressed air professionals, plant managers, plant engineers, service and maintenance managers, operations managers, auditors, and energy engineers in manufacturing plants and engineering/
consulting firms in the U.S. Contact Patricia Smith for subscription information at tel: 412-980-9902 or email: patricia@airbestpractices.com. REPRINTS: Reprints are available on a custom basis, contact Patricia Smith for a price
quotation at Tel: 412-980-9902 or email: patricia@airbestpractices.com. All rights are reserved. The contents of this publication may not be reproduced in whole or in part without consent of Smith Onandia Communications LLC.
Smith Onandia Communications LLC. does not assume and hereby disclaims any liability to any person for any loss or damage caused by errors or omissions in the material contained herein, regardless
of whether such errors result from negligence, accident, or any other cause whatsoever. Printed in the U.S.A.
airbestpractices.com 3
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FROM THE EDITOR COMPRESSED AIR BEST PRACTICES®
EDITORIAL ADVISORY BOARD
Danone North
Doug Barndt Energy Manager
America
Facilities Gentex
John Bilsky
Maintenance Corporation
Quality, Safety and Reliability Bhaskar Dusi
Corporate Energy
CEMEX USA
Manager
Winter is coming and the Compressed Air & Gas Institute’s Reciprocating
Richard Feustel Senior Energy Advisor Leidos
Air Compressor Section has sent us a useful article on how to prepare William Jerald Energy Manager CalPortland
reciprocating air compressors for reliable winter performance. Michael Jones
Director Corporate Intertape Polymer
Industrial Energy Managers
Energy Group
Robert Marsiglia, from Asahi America, has sent an interesting article Stanley Black
Robert Kirts GTS Energy Manager
& Decker
about the use of engineered polyethylene (PE) plastic piping material for Energy/Reliability
Kurt Kniss Shaw Industries
compressed air. The differences, under pressure, between PE and unsuitable plastic materials Engineer
Marshall
such as polyvinyl chloride (PVC) and chlorinated polyvinyl chloride (CPVC) are clearly Leslie Marshall Consultant
Consulting
pointed out. Group Energy Klöckner
Ethan O’Brien
Manager Pentaplast
Sticking with the safety topic, during my travels I’m pleased to observe the growing demand for Senior Utilities Nissan North
Brett Rasmussen
Engineer America
compressed air purity verification, via measurement and testing. We thank Jenny Palkowitsh, Director Energy
Brad Runda Purdue University
from the laboratory folks at Trace Analytics, for an article titled, “Pure Gas Testing-the Benefits & Utilities
Principal-Industrial
of Point of Use Sampling.” Bert Wesley, Sr. Plant Engineering
Woodard &
Curran
Practice Leader
VP, Global Marketing
Sustainability & Energy/Water Conservation David Andrews
& Communications
Sullair
Production equipment will consume significant portions of a company’s over-all energy and Steve Briscoe President
Compressed Air
Challenge
water-consumption footprint. Our own Mike Grennier was pleased to receive the opportunity to
Tilo Fruth President Beko USA
interview Tetra Pak’s Vice President of Liquid Food, Frederik Wellendorph, and write about their Blackhawk
Chris Gordon President
Compressed Air System Assessments
new portfolio of solutions designed to allow Ultra-Heat Treatment (UHT) milk processors save Equipment
Jan Hoetzel General Manager Airleader USA
energy and water – and reduce their overall carbon footprint by as much as 56%.
Paul Humphreys VP Communications Atlas Copco
Phil Kruger General Manager Harris Equipment
Jasween Jagjit-Webb, from Klüber Lubrication, has sent us an enlightening article about how
Sales & Marketing Parker GSF
the appropriate selection of high-quality air compressor lubricants can indeed contribute to John Lucidi
Manager Division
sustainability efforts. Wayne Perry Sr. Technical Director Kaeser
Total Equipment
Eric Solverson Vice President
Company
Thank you for investing your time
PneuTech
and efforts into Compressed Air Derrick Taylor Manager
Products
Best Practices. Jim Timmersman Senior Auditor
Power Supply
Industries
RODERICK M. SMITH Register at https://cabpexpo.com Jeff Yarnall Auditing Manager Rogers Machinery
Editor
tel: 412-980-9901
rod@airbestpractices.com
SFI-00993
2021 MEDIA PARTNERS
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CORPORATE GHG-REDUCTION NEWS*
Featuring: Signify, Merck and PepsiCo
* Scope 1 and 2 GHG Emissions from Direct Operations
Signify Achieves Carbon Neutrality so we need more companies to follow Signify’s so by increasing the energy efficiency of our
and Sets Course to Double Its Positive lead in setting their own net zero targets.” portfolio, which will reduce emissions of our
Impact on the Environment and Society customers, and by driving carbon reductions
Eindhoven, the Netherlands, September 8, 2020 “I’m extremely proud of all the Signify at our suppliers.
– Signify (Euronext: LIGHT), the world leader employees and thank them for supporting
in lighting, is proud to announce that it has our carbon neutrality objective. It is a truly We also call upon the world to accelerate
achieved carbon neutrality for all its operations significant achievement for us and we call on the adoption of affordable and clean energy
across the world as well as using 100% renewable many others to join us,” said Eric Rondolat, (SDG7). Our highly energy-efficient LED
electricity1. While the company progresses CEO of Signify. “However, the world is still lighting saves an average of 50% of the
towards its remaining commitments for 2020, it facing demographic change, urbanization, electricity consumed by conventional lighting.
will already embark on a new five-year journey climate change and resource scarcity. This is An additional saving of around 30% is
in which it will focus on doubling its positive not a time to pause and celebrate, but a time achieved by using connectivity and lighting
impact on the environment and society. to become even more ambitious and accelerate control systems. Moreover, we believe that the
our efforts to address these challenges. Growth expansion of solar-powered lighting systems
Signify achieves Carbon Neutrality for sustainability and providing a great place will provide another very effective opportunity
in September 2020 to work are firmly anchored as central parts to reduce carbon emissions.
Signify has reduced its operational emissions of our company strategy. This means that
by more than 70% since 2010, having shifted to when it comes to sustainability, we will go Double our circular revenues to 32%
more energy-efficient technologies at its sites, beyond carbon neutrality and double our – Making our economy more circular has
to more sustainable modes of transport and positive impact on the environment and on become more important than ever. Today
optimized logistics planning, and to less travel society in 2025.” we use 1.6 times the resources our planet
in a more sustainable way. It also uses 100% can sustain and resource scarcity and waste
renewable electricity, supported through two Brighter Lives, Better World 2025: Our have reached worrying proportions. We are
power purchase agreements, one in Texas and new sustainability program beyond committed to responsible consumption and
a second in Poland. The balance of emission carbon neutrality production (SDG12) with products that can be
reductions is achieved through a carbon Today, Signify starts implementing its new reprinted, refurbished, reused or recycled. This
offsetting program with projects aimed at sustainability program and sets course to will help us to achieve our goal of doubling
benefiting the wellbeing of local communities. double its positive impact on the environment our revenues from circular products, systems
and society. The UN Sustainable Development and services to 32% in 2025. This includes
“We would like to congratulate Signify on their Goals will be used as its strategic compass to revenues from 3D printed luminaires, which
fantastic achievement of carbon neutrality work towards the following four goals: we were the first lighting company to develop
across all operations in 2020. We have been at scale, and from streetlights with reusable
working in partnership with Signify for over Double the pace of the Paris Agreement – components and recyclable parts that we
10 years to accelerate the global adoption of As part of our commitment to climate action introduced earlier this year.
energy efficient LED lighting and through (SDG13), we will go beyond carbon neutrality
Signify’s support of RE100 and EV100,” said and reduce carbon emissions over our entire As part of our commitment to a circular
Helen Clarkson, CEO of The Climate Group. value chain. Already in 2025, we will achieve economy, we have also committed to
“The 2020s are the Climate Decade as we need the 2031 target set out for companies in the sustainable packaging, removing plastics from
to halve global emissions by 2030 to get us on Paris agreement to limit temperature rises all our consumer packaging before the end of
track to meet the goals of the Paris agreement, to 1.5˚C over pre-industrial times. We will do 2021, and to sending zero waste to landfill.
1. Cooper Lighting and Klite are not part of Signify’s EHS reporting yet. These two companies are currently being integrated and will be included in Signify’s annual reporting starting in 2021. The company aims to include them in its commitments in 2022.
6 airbestpractices.com
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Corporate GHG-Reduction News
Double our revenues for brighter lives, sales of EUR 6.2 billion, we have approximately transparently illustrates how the company is
through innovations that benefit society, 36,000 employees and are present in over 70 living up to its corporate responsibility and
to 32% – We are committed to supporting countries. We unlock the extraordinary potential of the progress the company has made towards
good health and wellbeing (SDG3) and light for brighter lives and a better world. We have achieving its goals.
sustainable cities and communities (SDG11). been named Industry Leader in the Dow Jones
We will double the percentage of our revenues Sustainability Index for three years in a row. More “The pandemic is showing us in no uncertain
for brighter lives, which benefit society, to information can be found at https://www.signify.com/ terms that technological progress and the
32%. This includes revenues from lighting global/our-company/investors/news positive force of science create sustainable added
innovations which increase food availability, value for society. At Merck KGaA, Darmstadt,
safety & security or health & wellbeing. Germany, we are also contributing to the efforts
Creating Sustainable Value: to fight the virus,” said Stefan Oschmann,
About Signify Merck Publishes Sustainability Chairman of the Executive Board and CEO.
Signify (Euronext: LIGHT) is the world leader in Report for 2020 “As a science and technology company, we take
lighting for professionals and consumers and lighting Darmstadt, Germany, April 13, 2021 – Merck on responsibility to find answers to the most
for the Internet of Things. Our Philips products, KGaA, Darmstadt, Germany, a leading science pressing challenges of our time. It is clear to us
Interact connected lighting systems and data-enabled and technology company, today published that sustainable entrepreneurship and profitable
services, deliver business value and transform life its Sustainability Report for 2020. The growth are not mutually exclusive, but rather
in homes, buildings and public spaces. With 2019 interactive online report comprehensively and mutually dependent.”
Merck KGaA, Darmstadt, Germany, presented
its new sustainability strategy in late 2020.
The company has consequently embedded the
topic as an essential element of its corporate
strategy. With the new strategy, it is pursuing
specific goals in the areas of science and
technology, value chain as well as climate
and the environment. In doing so, Merck
KGaA, Darmstadt, Germany, also intends
to make a clearly recognizable contribution
to the Sustainable Development Goals of the
United Nations.
In addition, the company has formulated
interim targets to support the achievement of
its environmental goals. By 2040, Merck KGaA,
Darmstadt, Germany, aims to achieve climate
neutrality. The company is thus planning to
reduce direct greenhouse gas emissions and
emissions from energy purchases (Scope 1 and
2) by 50% by 2030 compared with 2020. By
then, company also intends to reduce indirect
greenhouse gas emissions from the upstream
and downstream value chain (Scope 3) by a
total of 1,500 metric kilotons of CO2equivalents.
8 airbestpractices.com
WHAT
is Quincy Compressor?
We are innovators that develop solutions. Our philosophy has not changed
in the past 100 years. We were founded on the principals of problem solving.
We are in tune with our customers’ needs because we create products derived
from their problems. Our air systems are innovated in a way to set them apart
from anyone else in our industry.
We serve all industries including manufacturing, automotive,
and food and beverage. Looking for a solution to your problem?
Count on Quincy
quincycompressor.com
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Corporate GHG-Reduction News
Moreover, Merck KGaA, Darmstadt, Germany, intends to improve its
water efficiency and reduce its “Water Intensity Score” by 10% by 2025
compared with 2019.
Science & technology: Pioneer in the fight against
schistosomiasis
The 2020 Sustainability Report shows how Merck KGaA, Darmstadt,
Germany, is developing products and technologies aimed at improving
people’s lives. To improve the health of underserved populations in low-
and middle-income countries, it is collaborating closely with numerous
partner organizations. The company is developing integrated solutions,
such as medicines, diagnostic procedures, technologies, and methods
of infectious disease control, both against the tropical parasitic
disease schistosomiasis and against malaria. In 2020, Merck KGaA,
2022 EXPO Darmstadt, Germany, donated approximately 226 million tablets to
treat schistosomiasis in 30 countries. Moreover, its “Open Innovation”
initiative enables the exchange of intellectual property. This means
JAN 31-FEB 2 medicines can be discovered more quickly for diseases that require a
high degree of medical intervention. In this context, the company is
initially focusing on neglected tropical diseases.
To enable sustainable innovations, Merck KGaA, Darmstadt, Germany, has
developed the Design for Sustainability (DfS) program, for example. This
is a comprehensive method to improve the sustainability of Life Science
products by analyzing various sustainability criteria.
Value chain: Securing social, ethical and ecological standards
In 2020, Merck KGaA, Darmstadt, Germany, worked with approximately
60,000 suppliers in nearly 160 countries. As part of the Together for
Attend the premier Sustainability (TfS) initiative launched by the chemical industry, the
event for HVACR company is calling on its suppliers to be evaluated using self-reported
information or audits. Evaluation criteria include environmental aspects,
labor and human rights, ethics, and sustainable procurement.
Register now at ahrexpo.com
The online tool DOZN™ makes it possible for the company to evaluate
sustainable alternatives to various chemicals. The tool is also available
to customers and creates new possibilities for sustainable product
design. Users can evaluate their own products and processes and
make more environmentally sustainable decisions regarding their
development processes.
Climate & environment: Environmental targets exceeded
Merck KGaA, Darmstadt, Germany, exceeded its environmental targets
for 2020. Excluding the legacy Versum business, the company lowered its
10 airbestpractices.comDive into clean, fresh compressed air 100% oil-free sustainable technology At Sulzer, our goal is to offer smart technology that supports sustainable development. Our HSR turbocompressors do just that. Driven by a high-speed, premium efficiency motor with digitally controlled magnetic bearings, the HSR turbocompressor does not experience mechanical friction or wear. It helps you reduce energy consumption, lower your operating and maintenance costs and increase uptime. Want to experience the best total output for your energy input? Explore the HSR range at www.sulzer.com/hsr.
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Corporate GHG-Reduction News
greenhouse gas emissions (Scope 1 and 2) by projects were carried out in 96 countries PepsiCo Announces Strategic
25% relative to the 2006 baseline. A reduction around the world. As part of this, Merck End-To-End Transformation: pep+
of 20% was planned. Merck KGaA, Darmstadt, KGaA, Darmstadt, Germany, supports people (PepsiCo Positive)
Germany, cut its water consumption at sites in in need in the vicinity of its sites and provides PURCHASE, N.Y., Sept. 15, 2021: PepsiCo,
water-stressed areas by 27% relative to the 2014 disaster relief. Last year, community outreach Inc. (NASDAQ:PEP) today introduced pep+
baseline; a reduction of 10% was planned. With activities by Merck KGaA, Darmstadt, Germany, (pep Positive), a strategic end-to-end
respect to waste disposal, the company believes encompassed projects worth approximately € transformation with sustainability at the
that it is well on track to lowering its key waste 54 million in total. In the fight against Covid- center of how the company will create growth
management indicator, the “Waste Score”, by 19, the company donated 2 million protective and value by operating within planetary
5% by 2025. At the end of 2020, Merck KGaA, face masks to healthcare providers. In more boundaries and inspiring positive change for
Darmstadt, Germany, had already achieved a than 30 countries, Merck KGaA, Darmstadt, the planet and people. pep+ will guide how
reduction of 4.6%. Germany, teams initiated numerous donation PepsiCo will transform its business operations:
campaigns, which collected several million from sourcing ingredients and making and
Community outreach: 274 projects euros in cash and goods. selling its products in a more sustainable
in 96 countries way, to leveraging its more than one billion
Merck KGaA, Darmstadt, Germany, clusters The Sustainability Report 2020 can be viewed at connections with consumers each day to take
its community outreach activities under the https://www.emdgroup.com/en/news/sustainability- sustainability mainstream and engage people
heading “Our Good Deeds”. In 2020, 274 report-2020-04-13.html to make choices that are better for themselves
and the planet.
“pep+ is the future of our company – a
fundamental transformation of what we
do and how we do it to create growth and
EXPERIENCE. CUSTOMER. SERVICE..
shared value with sustainability and human
capital at the center. It reflects a new business
Paying too much for reality, where consumers are becoming more
LIQUID NITROGEN?
interested in the future of the planet and
society,” said Ramon Laguarta, PepsiCo’s
Chairman and CEO. “pep+ will change our
brands and how they win in the market. For
Generate your own supply of example, imagine Lay’s will start with a potato
FOOD GRADE NITROGEN GAS grown sustainably on a regenerative field, and
for all of your packaging requirements. then be cooked and delivered from a Net-Zero
and Net Water Positive supply chain, sold in a
bio-compostable bag, with the lowest sodium
levels in the market. That’s a positive choice.
ROI
RELIABLE EASY 6-24
That’s the best tasting, #1 potato chip of the
DELIVERY INSTALL MONTHS future. That’s how pep+ will be better for
people, for the planet, and for our business.
Now, imagine the scale and impact when
applied to all 23 of our billion-dollar brands.”
www.n-psi.com
704.897.2182
inquiry@n-psi.com
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N , O I L - F REE
CLEA S E D AIR
COM P R E S
1 SS-0
CLA
ISO 8573-
Ramon Laguarta, Chairman & CEO, PepsiCo
pep+ drives action and progress across three key pillars, bringing
together a number of industry-leading 2030 goals under a
comprehensive framework:
p Positive Agriculture: PepsiCo is working to spread
regenerative practices to restore the Earth across land equal to
the company’s entire agricultural footprint (approximately 7
million acres), sustainably source key crops and ingredients,
and improve the livelihoods of more than 250,000 people in its
agricultural supply chain.
p Positive Value Chain: PepsiCo will help build a circular
and inclusive value chain through actions to:
` Achieve Net-Zero emissions by 2040;
` Become Net Water Positive by 2030; and
` Introduce more sustainable packaging into the value chain.
• PepsiCo announced today new goals to cut virgin plastic
per serving by 50% across its global food & beverage
portfolio by 20301, using 50% recycled content in
its plastic packaging and scaling the SodaStream
business globally, an innovative platform that almost
entirely eliminates the need for beverage packaging,
among other levers.
hertz-kompressoren.us
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Corporate GHG-Reduction News
` The company will also progress its positions in Mexico, China and “pep+ directly links the future of our business
more than $570 million diversity, several Western European markets; with the future of our planet, for the benefit
equity and inclusion journey; and of both – from how we source ingredients and
` Accelerating its reduction make and sell our products; to how we inspire
` Today introduced a new global of added sugars and sodium consumers through our iconic brands to make
workforce volunteering through the use of science-based better choices for themselves and the planet;
program, One Smile at a Time, to targets across its portfolio and to how we support communities and improve
encourage, support and empower cooking its food offerings with livelihoods throughout our supply chain,”
each one of its 291,000 employees to healthier oils; and said Jim Andrew, Chief Sustainability Officer,
make positive impacts in their local PepsiCo. “Take SodaStream, for example. By
communities. ` Continuing to scale new business rapidly expanding the SodaStream ecosystem,
models that require little or no we are meeting the needs of consumers at
p Positive Choices: PepsiCo continues to single-use packaging, including home, away from home, and on-the-go. At the
evolve its portfolio of food & beverage its global SodaStream business – an same time, we are also offering consumers
products so that they are better for the icon of a Positive Choice and the positive choices that use less plastic, create
planet and people, including by: largest sparkling water brand in fewer emissions, and are better for people.
the world by volume. SodaStream, pep+ is our roadmap to create the food and
` Incorporating more diverse already sold in more than 40 drinks people love in a way that helps build the
ingredients in both new and countries, is bringing PepsiCo sustainable future we all must have.”
existing food products that are flavor options like Pepsi Zero Sugar,
better for the planet and/or deliver Lipton and bubly to 23 markets, and The company’s brands across its food &
nutritional benefits, prioritizing its new SodaStream Professional beverage portfolio are accelerating their efforts
chickpeas, plant-based proteins and platform will expand into to realize PepsiCo’s sustainable packaging
whole grains; functional beverages and vision and leveraging their influence to educate
reach more than 10 additional consumers on recycling and the planetary
` Expanding its position in the markets by the end of 2022, part of impacts of their choices.
nuts & seeds category, where the brand’s effort to help consumers
PepsiCo is already the global avoid more than 200 billion p 11 European markets are moving
branded leader, including leadership plastic bottles by 2030. key Pepsi-branded2 products to
100% rPET bottles by 2022. PepsiCo
estimates that shifting to a 100% rPET
bottle will lower GHG emissions by
approximately 30% per bottle.
p In the U.S., all Pepsi-branded
products will be converted to
100% rPET bottles by 2030, with
Pepsi Zero Sugar beginning to be sold
in 100% rPET bottles by 2022. The
brand is celebrating this important
move to sustainable packaging with
a new consumer-centric platform
leveraging fall football and driving
recycling awareness, education and
14 airbestpractices.com1 0 / 2 1
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advocacy, which are critical because
rPET availability depends on consumers’
commitment to recycling.
p PepsiCo has been investing in
breakthrough food packaging
technology and is now introducing
a fully compostable bag made with
plant-based materials. Starting with
Off The Eaten Path, one of Frito-Lay’s
plant-based brands, this industrially
compostable packaging will be available
to consumers in the U.S. at Whole Foods
stores beginning this month. Notably, the
company also announced today that it
is willing to work with other companies
to license the same technology at no
cost given the importance of creating
a circular food packaging system.
To learn more about the pep+ agenda, please visit
www.pepsico.com/pepsicopositive.
About PepsiCo
PepsiCo products are enjoyed by consumers more
THAT’S THE TRUE MEANING OF RELIABILITY
than one billion times a day in more than 200
countries and territories around the world. PepsiCo
generated more than $70 billion in net revenue in
2020, driven by a complementary food and beverage
portfolio that includes Frito-Lay, Gatorade, Pepsi-Cola,
Quaker, Tropicana and SodaStream. PepsiCo’s product
portfolio includes a wide range of enjoyable foods and
beverages, including 23 brands that generate more
EXPLORE THE BROAD RANGE OF NEW SULLAIR COMPRESSORS AT SULLAIR.COM
than $1 billion each in estimated annual retail sales.
Guiding PepsiCo is our vision to Be the Global Leader
in Convenient Foods and Beverages by Winning with
Purpose. “Winning with Purpose” reflects our ambition
to win sustainably in the marketplace and embed
purpose into all aspects of our business strategy and
brands. For more information, visit www.pepsico.com.
1. Against 2020 baseline.
2. Includes Pepsi, Pepsi MAX, Pepsi MAX Lime, Pepsi MAX without caffeine, Pepsi
Light, Pepsi Light without caffeine.
© 2020 Sullair, LLC. All rights reserved.
airbestpractices.com 15
020526_Sullair_Brand Message Ad Concepts_2020_4.875x9.875.indd 1 10/5/20 12:00 PM| 1 0 / 2 1 SUSTAINABILITY & ENERGY/WATER EFFICIENCY
F ood & B everage P rocessing
& P ackaging M onthly F eature
Tetra Pak Solutions Conserve Water &
Energy for Food & Beverage Sector
By Mike Grennier, Compressed Air Best Practices® Magazine
c For Tetra Pak, looking inward is a given
when it comes to protecting the planet – yet
the global processing and packaging company
also appreciates the need to look outward to
enhance its sustainability efforts across its
entire value chain.
Tetra Pak believes the best way to make a
positive environmental impact is a holistic
approach, whether that means maintaining
its own energy-and water efficient operations,
working with partners and suppliers to promote
renewable materials, or helping customers
achieve their own sustainability ambitions,
said Frederik Wellendorph, Vice President
Liquid Food, Tetra Pak.
The Tetra Pak® UHT 2.0 heating portfolio helps UHT milk processors conserve water and energy.
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“Our view is always from the perspective of Sustainability has always been at the core
the value chain from the raw materials to the of how Tetra Pak operates its business. The
end product,” Wellendorph said. “How do we company began collecting data on energy use
work with our suppliers who supply us? How and Greenhouse Gas (GHG) emissions annually
do we look at our own manufacturing to avoid since 1999. At its own facilities, the company
waste? Then, how can our equipment minimize invested $22 million into energy efficiency since
the amount of energy or water it uses when 2011, which prevented energy use increasing
processing and packaging customers products? by 23% to date. In 2020, its use of renewable
It’s more than just focusing on ourselves.” electricity sources stood at 83%, up from
69% in 2019, and is expected to reach 100%
Doing the Right Thing before 2030. Its goal is to reach net zero GHG
With its headquarters in Lausanne, emissions at its operations by 2030, with the
Switzerland, Tetra Pak (www.tetrapak.com) ambition to achieve net zero GHG emissions
employs over 25,000 people in 160 countries. for the entire value chain by 2050.
Its processing and packaging solutions
are used in the production and delivery of “Using renewable resources and making sure
numerous products, including beverages, we run our operations in a sustainable way is Frederik Wellendorph, Vice President Liquid Food,
milk, ice cream, cheese, powder products, the right thing to do,” said Wellendorph. Tetra Pak.
prepared food, and many others.
Sullivan-Palatek Distributors Bring Value to Customers
Compressed air systems can be complex; that’s why our Distributor network is key to
providing end-users with the best compressed air solution for their businesses.
Advantages of purchasing a Sullivan-Palatek air compressor through our Distributors:
» Appropriate product selection recommendations, including sizing and feature specification
» Integration of all components of your compressed air system
» Operating parameters adjustments, including pressure and modulation
» Installation and electrical connection solutions
» After-the-sale customer service and technical support
To connect with your local Distributor, start here
https://www.sullivan-palatek.com/contact-sales-directors/
To read about how our Distributors can benefit you Dependable by design.TM
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© 2021 Sullivan-Palatek, Inc.
2021-04_Ad_Horizontal_CABP-3.indd 1 2/26/2021 9:44:47 AM
airbestpractices.com 17| 1 0 / 2 1 SUSTAINABILITY & ENERGY/WATER EFFICIENCY
Tetra Pak Solutions Conserve Water & Energy for Food & Beverage Sector
In addition to operating resource-efficient
facilities, a second component of Tetra Pak’s
sustainability strategy is a commitment to a
low-carbon circular economy that considers
not just recycling and reuse of materials, but
also the climate impact of raw materials and
manufacturing.
The strategy is particularly crucial to
sustainability goals concerning its carton
packages. As an example, Tetra Pak began to
restructure its packaging innovation strategy
in 2018 around the ideal beverage carton:
a fully renewable and recyclable package.
Since then, it has significantly accelerated
development efforts and increased investments
to achieve its vision. Its goal is to field-test an
aseptic package made entirely from renewable
Tetra Pak’s E3/Speed Hyper packaging machine uses eBeam technology to sterilize packaging material with electronic sources by 2022.
beams versus the traditional hydrogen peroxide sterilization process. The result is significant energy savings.
Saving Energy and Water in UHT
Milk Processing
Aside from efficient operations and better
carton packages, a critical aspect of Tetra
Pak sustainability strategy involves ongoing
development of solutions to help milk and
beverage processors, as well as other customers,
achieve their own sustainability ambitions.
Recently, the company introduced its UHT
2.0 portfolio, which in combination with E3/
Speed Hyper packaging equipment, helps
Ultra-Heat Treatment (UHT) milk processors
reduce electrical consumption by as much
as 31%, steam by up to 78% and freshwater
consumption up to 40% when compared with
the traditional UHT production process. By
using the new technology versus the traditional
approach to UHT milk production, producers
stand to reduce their carbon footprint by as
much as 56%.
Commonly found throughout Europe, UHT milk
is produced using a process that allows milk
to be packaged in sterile containers and stored
18 airbestpractices.comSUSTAINABILITY & ENERGY/WATER EFFICIENCY 1 0 / 2 1
|
Companies that produce Juice, Nectar and Still Drink (JNSD) beverages can save water and energy with Tetra Pak’s new JNSD processing solution.
unrefrigerated without spoilage for as long as – Tetra Pak determined production efficiencies UHT Milk Production 2.0
nine months. By contrast, pasteurized milk were to be gained, Wellendorph said. Tetra Pak’s approach to conserving energy
common to North America and other areas of and water in UHT milk processing reduces the
the world requires refrigeration and offers a “Energy and water savings are extremely number of steps involved in production, which in
limited shelf life of approximately two weeks important to dairy operators,” he said. “They turn, reduces the resources and costs involved.
after processing. are always targeting OPEX costs. How can we
minimize the use of water, steam, chemicals, UHT milk processing involves heating raw
Given its experience with traditional UHT milk detergents? How can we improve the ratios?” milk to higher than 275˚F (135˚C) for
processing – and its goals in helping producers approximately one second, cooling it rapidly,
rogers-machinery.com
airbestpractices.com 19| 1 0 / 2 1 SUSTAINABILITY & ENERGY/WATER EFFICIENCY
Tetra Pak Solutions Conserve Water & Energy for Food & Beverage Sector
and then aseptically packaging the milk into If a processor starts production of UHT milk
sterile containers. The continuous process is with powder versus raw milk, UHT 2.0 with
also used commonly used in processing fruit OneStep technology can be used to combine
juices and other liquids. concentrate mixing with in-line blending,
also without the need for pasteurization or
With traditional UHT milk processing, raw milk storage tanks. By adding different streams in
is typically preheated from 42˚F (5˚C) to 190˚F the blending steps, such as a chocolate slurry
(90˚C) using tubular or plate heat exchangers. or protein concentrate, processors can also
The next step involves homogenization (also produce a range of value-added products.
called separation) in order to separate the
fat in milk and increase the product’s storage Fewer Steps Saves Resources
stability. Depending on the system used, Although the potential energy and water savings
homogenization occurs before or after the – as well as operational costs – vary based on
pasteurization. In the pasteurization stage, the uniqueness of each UHT processing plant
the milk is heated using either direct or and its geographic location, the Tetra Pak
indirect heating systems to reach the targeted solution offers the opportunity for most to come
temperature of 275˚F (135˚C). With direct out ahead given the reduction in processing
heating, the product is put into direct contact steps, said Wellendorph.
with hot steam. Indirect heating is performed
with tubular or plate heat exchangers. “We found we can cut out the middle step,
which is from the point when raw milk is
After pasteurization, the milk is cooled to the received until it gets ultra-high treated.
original temperature of the raw milk. From We’ve eliminated the pasteurization step
there it enters the standardization process, and eliminated storage,” he said.
which adjusts the constituents of milk to reduce
butterfat content. It is then regeneratively Wellendorph said a processor’s decision to
cooled and held in storage in aseptic tanks install UHT 2.0 solution is typically driven by
until it is sent to an aseptic packer. the addition of an entirely new production
line, or replacement an old production line
Unlike the traditional process, Tetra Pak’s UHT due to the economies of scale. Regardless the
2.0 with its “OneStep” technology eliminates the reasons for installing the technology, he said
need for pasteurization, as well as storage. In a less processing and storage equates to more in
single, unbroken step, the raw milk is pre-heated, terms of energy and water savings.
separated, standardized, and homogenized,
before being sent to a UHT treatment unit where “Every time you have a vessel, and you
S-4 Series: the milk is heated to 275˚F (135˚C) and then have a pipe, and a pasteurizer, it needs to
Fixed & Variable Speed cooled. The milk is then transferred to aseptic be cleaned quite frequently. Cleaning also
Quiet · Direct Coupled · Efficient tanks as with the traditional UHT milk process. requires heating up and cooling down. That
Additionally, the solution includes a Tetra Pak® costs energy, that costs water, that is a waste
E3/Speed Hyper packaging equipment, which of raw materials. It’s unavoidable,” he said.
uses eBeam technology. Developed by Tetra Pak “With this technology, energy consumption
For more information on our complete in combination with partner company COMET, can be reduced by as much as a third and we
product offering please contact us:
eBeam technology sterilizes packaging material can more than halve the water usage when it
Phone +1 770-874-1570
using electronic beams, replacing the traditional comes to cleaning. That translates into a near
www.boge.com/us hydrogen peroxide sterilization process. 60% reduction in a plant’s carbon footprint.”
20 airbestpractices.comSUSTAINABILITY & ENERGY/WATER EFFICIENCY 1 0 / 2 1
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Saving Energy and Water in JNSD whether to use the Tetra Pak solution given the processing UHT milk, Wellendorph said the
Beverage Processing different processes and conditions involved. trend in the beverage processing industry is
While the UHT 2.0 portfolio gives UHT milk pointing strongly toward a future focused on
producers another method to minimize their “It can work on juice in general. As long as continued sustainability.
environmental impact and reduce operational it’s from concentrate, it’s possible, but you
costs, Tetra Pak has also introduced a similar really need to understand how to design a safe, “It’s about taking steps to find solutions. It’s a
solution for companies that produce Juice, hygienic plant, as well.” big decision to invest in technologies like these,
Nectar and Still Drink ( JNSD) beverages. but it will be the future. It will come.”
Whether it’s Tetra Pak’s new solution for
The solution meets the growing demand JNSD beverage processing, or a new option for All photos courtesy of Tetra Pak.
for sustainable methods of producing this
category of beverages, which are made from
concentrates. The beverage category consists To read similar Food Industry articles visit https://www.airbestpractices.com/industries/food
of juice, which is extracted from the pulp
of fruits; nectar, which is a non-carbonated
drink that contains some fruit juice and other
ingredients such as water and sweeteners; and Visit our Webinar Archives to listen to expert presentations on Compressed Air
Energy Conservation at https://www.airbestpractices.com/magazine/webinars
still drinks, which are non-alcoholic beverages
without carbonation.
In traditional methods used to process JNSD
beverages the full volume of juice concentrate
and water is pasteurized. The new Tetra Pak
solution, however, pasteurizes only the juice
concentrate and not the entire volume of
concentrate and water. The water is also treated
with an optimized UV light and filtration. The
process then blends the concentrate and water Protect your valuable
aseptically in line after the treatments. equipment with oil-
less scroll and piston
Wellendorph said the first-of-its-kind air compressors
process drastically reduces energy and water
from ANEST IWATA.
consumption, which in turn, can reduce a
Quiet, reliable, energy
processing plant’s production costs and its
efficient & Class Zero
environmental impact.
Oil-Free.
“This technology will have a massive impact on
a plant’s energy consumption,” he said. “With
standard orange juice made from concentrate,
we have tested the process and seen nearly a 70%
reduction in energy use. Plus, water consumption
has been reduced by more than half.”
www.anestiwata.com
Wellendorph points out the need for JNSD Toll free: 800-440-0282
beverage plants to factor in safety when deciding Interested in becoming a distributor?
airbestpractices.com 21| 1 0 / 2 1 QUALITY, SAFETY & RELIABILITY
Preparing Reciprocating
Air Compressors for Winter
By the Compressed Air & Gas Institute
c Are you preparing for winter? Your your system is not in a temperature-controlled operation. A clog can lead to contamination
reciprocating air compressor needs indoor environment, your machine could and cause pressure drops. Ensure your oil is
to as well. sustain short-term and long-lasting damage. rated for ambient temperatures and consistently
The colder months are upon us, and your remains fluid
compressed air system maintenance routine Here is a list of best throughout
can be more complex in colder climates. practices for preventative
Freezing temperatures can have negative maintenance in cold
effects on your reciprocating air compressor, weather in order to
dryer, and many accessories. One of the maintain efficiency
best practices to adopt is keeping a detailed and ensure consistent
maintenance log. At the end of each season, operations:
take note of the condition your equipment
is in, and address it promptly using the 1. Change Filters
manufacturer’s instructions to keep it and Oil
operating smoothly and efficiently. Clear air filters are
essential to your system’s
Most reciprocating compressors are designed Most reciprocating compressors
to operate in temperatures above 40˚F (4˚C). If are designed to operate in
temperatures above 40˚F (4˚C).
22 airbestpractices.comQUALITY, SAFETY & RELIABILITY 1 0 / 2 1
|
the season. Lubricant can thicken during colder weather can cause frozen moisture
weather, causing your reciprocating compressor to accumulate on or in your
to be less effective and overload the motor, reciprocating air compressor.
putting undue wear on the compressor. This freezing and thawing
of the moisture will cause
2. Clean the Exterior stress on the components
Keeping the outside of your reciprocating of the equipment. The stress
compressor clean can prevent corrosion and from freezing and thawing can
make it easier to spot oil leaks. It also allows compromise the equipment’s
you to examine all the air compressor’s structure and weaken it
components for safety concerns, as well as prematurely.
wear and tear. Along with the exterior, check
the feet and mounting of the reciprocating When you properly prepare
compressor. Worn or damaged feet can cause and maintain your compressed
unnecessary vibration, which could lead to
operational issues. Maintaining air compressor room
temperature around 45˚F (7˚C) will significantly
assist in keeping your system up and running.
3. Check Compressed Air Dryers, System
Drains, and Tanks for Moisture
In cold weather conditions, dryers and drains
must be closely monitored, as they cannot ONDEMAND • RELI
ABLE • EFFI
CIENT
properly operate below 32˚F (0˚C) without
proper freeze protection. The heat exchanger
Poi
nt-
Of-UseCompressedAirDryi
ngSoluti
ons
in a dryer can become damaged and blocked
when moisture is allowed to freeze. Freezing in ForMoist
ureSensit
iveAppli
cat
ions
a refrigeration dryer can also cause cracking Cl
ean,DryAirYouNeed-WhenYouNeedI t
and damage to components. In extremely cold
weather, drain valves can also freeze open or Desi
ccantAi
rDr
yer
s
closed, preventing proper operation. Freezing 0.
40-3000SCFM
in drain valves can also cause cracking in the
housing, requiring repair resulting in downtime. -40°F/
CPressur
e
Tanks can also collect condensation that is Dewpoi
ntSt
andard
susceptible to freezing, and therefore, it must be
checked regularly during the colder months. Mi
nimi
zeEner
gyConsumpti
on
&Wastef
ulPur
geAir
4. Weatherproof the Air Compressor Room
Consider providing ambient temperatures CompactDesignswi
th
around your compressed air system by Ver
sat
il
eInst
all
ati
onOptions
installing heaters or proper ventilation
methods. This space does not need to be heated
to the same levels required for human comfort.
However, maintaining the room temperature MadeI
nU.
S.A.
around 45˚F (7˚C) will significantly assist in
keeping your system up and running. Freezing 1-
800-
521-
5351 www.
Alt
ecAI
R.com
airbestpractices.com 23OPTIMIZE
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CAGI’s personnel certification program for compressed air the industry who design, service, sell, and install compressed air
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*Compressed Air Challenge workshop only open to distributors, engineering firms/consultants and manufacturing personnel who are paid registrants of the full conference package. Not available to single-day registrants.QUALITY, SAFETY & RELIABILITY 1 0 / 2 1
|
Preparing Reciprocating Air Compressors for Winter
air system during the colder months, you and p Energy savings Remember, when performing maintenance on
your company will benefit from the following: equipment, always ensure your unit is off and
p Environmentally sound operation disconnected from the power source.
p Consistent production and limited
downtime Every manufacturer has a specific For more information, visit the CAGI website
maintenance schedule and safety requirements at www.cagi.org.
p Reduced operational or repair costs to do proper service. Always refer to the
original manufacturer’s operator manual All photos are courtesy of the Compressed Air
p Reduced moisture damage on products before performing service or repairs. and Gas Institute..
To read similar Air Compressor Technology articles, visit
https://www.airbestpractices.com/technology/air-compressors
For expert presentations, visit our Webinar Archive Section dedicated to Air
Compressor Technology at https://www.airbestpractices.com/magazine/webinars
The Compressed Air and Gas Institute
(CAGI) is the united voice of the compressed
air industry, serving as the unbiased FOCUSED ON
authority on technical, educational,
promotional, and other matters that affect
PERFORMANCE
compressed air and gas equipment suppliers
Parker’s PPD Series of Portable
and their customers. CAGI educational Desiccant Compressed Air Dryers
are comprehensive compressed air
resources include e-learning coursework, treatment systems each equipped with
selection guides, videos and the Compressed multiple stages of a filtration and a twin
tower adsorption dryer for compressed
Air & Gas Handbook. air dehumidification. Packaged on
portable, heavy-duty skid these highly
engineered systems ensure high quality
The Reciprocating Compressor Section compressed air in accordance with
ISO8573-1, the international standard
consists of the following member companies: for compressed air quality.
p Atlas Copco Compressors LLC
p FS-Curtis
p Gardner Denver, Inc. parker.com/igfg
p Ingersoll Rand 800.343.4048
p Quincy Compressor
p Saylor-Beall Manufacturing Co.
For more information, visit the CAGI
website at www.cagi.org.
ADV_CABP_PPD_Print_092021.indd 1 7/27/2021 1:10:52 PM
airbestpractices.com 25| 1 0 / 2 1 SUSTAINABILITY & ENERGY/WATER EFFICIENCY
Promote Sustainability with an
Optimal Air Compressor Lubricant
By Jasween Jagjit-Webb, Market Manager-
Air Compressor Lubricants, Klüber Lubrication
c When facilities look to improving In an effort to reduce costs, users often operational costs, an overlooked root cause of
sustainability, they tend to focus first on buy standard, all-purpose mineral oils for air compressor downtime or failure can be the
traditional energy utilities – natural gas, lubricants regardless of the air compressor choice of lubricants. Purchasing a high-quality
heating oil, electricity and water. As facilities application. While this practice initially lowers synthetic lubricant formulated specifically for
achieve greater sustainability through
efficiencies that reduce utility energy waste
and minimize the plant’s carbon footprint,
they begin to focus on other energy sources,
including compressed air, to enhance
sustainability efforts.
Facility engineers recognize that they can
lower energy costs by recovering the heat
generated by the air compressor, the heart
of many critical commercial and industrial
processes. They understand that the efficient
operation of this vital power source can play a
role in meeting sustainability goals. However,
they may not recognize the importance of the
lubricant – the lifeblood of the air compressor
– in promoting efficient operation.
Air compressor lubricants can promote sustainability.
26 airbestpractices.comSUSTAINABILITY & ENERGY/WATER EFFICIENCY 1 0 / 2 1
|
the air compressor application can ultimately and are more likely to evaporate and be used by poor compressor maintenance, but
reduce Total Cost of Ownership (TCO). up quickly. Standard mineral oils contain also by using mineral oils and synthetic
sulfur, nitrogen, and oxygen, which collectively products that are prone to oxidation.
The Role of Air Compressor Lubricants increase acid development, oxidation, and When inferior products are used in high
Air compressor lubricants have four key roles: buildup (sludge). The molecular composition heat applications, the oil and varnish
of standard oils tends to cause inconsistencies break down more quickly and require
1. Coating to inhibit corrosion in surface lubrication that increases friction more frequent changeouts that increase
2. Coolant to remove heat between air compressor parts. equipment downtime.
3. Lubrication to minimize friction
4. Sealant to prevent air leakage The Benefits of Synthetic Lubricants The oxidative stability of many synthetic
Optimized for Applications lubricants contributes to their high
Standard mineral compressor oils are suitable The benefits of synthetic lubricants chosen usage per hour, extending parts life and
for applications that don’t require continuous for specific commercial manufacturing and lowering the costs of parts over the life
use. However, their composition makes them industrial applications include the following. of the compressor. Selecting a high-
an inherently poor choice for industrial performance synthetic lubricant with
applications. Mineral oils have low transfer 1. Oxidation Resistance additives that minimize oxidation can
properties, which cause them to overheat. Sludge is a common problem in air increase uptime, save on parts cost and
They are volatile with low flash temperatures compressor use. It is caused not only thereby contribute to sustainability goals.
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airbestpractices.com 27You can also read
